pKa buffered flavor enhanced reduced moisture fruits and vegetables

This application claims the benefit under 35 USC 119(e) of U.S Provisional Application No. 60/595,258, filed Jun. 20, 2005. This application is also a continuation-in-part of U.S. patent application Ser. No. 11/423,728 filed Jun. 13, 2006 and U.S. patent application Ser. No. 11/382,051, filed May 7, 2006, which claims the benefit of U.S. Provisional Application No. 60/595,072, filed Jun. 3, 2005.

The field of invention relates generally to a combination of partial drying and quick-freezing which adds unique and functional benefits to frozen fruits and vegetables. Partial drying removes surface moisture with little or no shriveling while reducing weight and concentrating flavor and color. Smaller and fewer ice crystals are generated resulting in minimal cell structure damage and prevents the development of free moisture (weeping, purging or syneresis) upon thawing.

Additional functional benefits for flavor, color and texture of reduced moisture fruits and vegetables are achieved by modifying the natural pH via altering the pKa, hydrogen ion balance, acidity and solids of the incoming raw material prior to processing into reduced moisture frozen fruits and vegetables.

The slight modification of weak acids via this invention improves the overall flavor and allows weaker flavors to be generated which were masked by the stronger acids naturally occurring in the vegetable pieces.

FIG. 1 SHUGI PROCESS FLOW DIAGRAM, shows process flow from wet processing into dry processing with final product being held by QA until all process records and laboratory results are reviewed.

FIG. 2 SHUGI OVERALL PROCESS SYSTEM FLOW, for the present invention.

FIG. 3 FRUIT/VEGETABLE PROCESS FLOW, showing the application of the present invention.

The process for additional functional benefits is achieved by incorporating various solutions that are applied to the cut fruits and vegetables prior to moisture reduction and individual quick freezing.

The application of the solutions utilizes a spray system to lightly coat the individual fruit and vegetable pieces at a concentration of 0.006% to 1.5%. The application rates and solutions vary by vegetable and fruit as well as piece size. The incoming raw material is tested for solids, total acidity and pH. Solutions are prepared to meet the desired finished product attributes for color, flavor, texture, solids, pH, total acidity and syneresis. The pH (acidity) targets are established for each finished product in a range from 2.5% to 25.0%. Solids targets are established for each product to achieve a 10.0% to 150.0% increase in solids and free moisture removal.

The raw material is prepared using conventional methods for sorting, washing and sizing. The solutions are prepared and constantly mixed utilizing industry standardized tanks, pumps and nozzles for application to the fruits and vegetables. The treatment solutions are applied by spray nozzles as the prepared raw material passes under them on a standard conveyor belt. The use of calcium chloride to improve the texture and firmness of vegetables is well know and commonly used in tomato processing and some other vegetables. The resulting off flavors from calcium chloride is recognized and to date no solution has been found to achieve the texture with out some off flavors being generated. The proposed invention combines several process treatments and a flavor modifying solution to achieve the textures and desired flavors of the finished fruits and vegetables.

The complete process requires 5 steps to achieve the pH buffering, pKa acid balance, solids, color, flavor and texture improvement.

(1) Examples 1, 2 and 3 show USP mineral powders that are dry blended by weight. Spray dried in a Shugi, FilterMat or other acceptable agglomerator to less than 5.0% moisture into a firm granule. Dry blend in 5.10% DC ascorbic acid and 0.20% vitamin D 3 . (2) Combine the finished agglomerated blend into a solution of 37.0% CaCl 2 at 0.002% to 0.004% by weight. This mixture is continuously agitated to insure good mixing and uniformity of the formula. (3) This mixture is sprayed onto the prepared vegetables or fruits to achieve a 0.7 to 1.5% solution. (4) Partial drying is achieved utilizing a belt dryer, bin dryer or tray dryer to reduce moisture from 10% to 50% of the incoming free moisture of the treated fruit or vegetable. The finished vegetable will have a solids level that is 40 to 50% greater than the initial raw material. e.g., tomato: incoming solids 5.5% finished solids 10.0 to 12.5% (5) The treated and partially dried fruit or vegetable pieces are passed through a specialized hot air pasteurization unit to achieve a microbiological reduction process lethality) step of >15,000 total plate count prior to individual quick freezing. This insures that the vegetable piece is free of pathogens and results in a significant reduction of bacteria commonly found in process fruits and vegetables.

This process has been successfully tested and used on tomato, broccoli, eggplant, cauliflower, green and yellow zucchini, green, red and yellow bell pepper, jalapeno, green chili, strawberry, peach and apricot. The resulting finished products exhibited higher solids (10.0% to 40.0%), a pH change of (10.0% to 40.0%), better color, flavor and texture. The products were further tested in various formulas and applications where better retention of these characteristics was desired. The treated products held up better under additional thermal reprocessing, refreezing, in shelf stable refrigerated applications and in a thawed state for immediate consumption.

The vitamin C and vitamin D function to improve the absorption of CaCO3, MgOH and KOH into the vegetable pieces to improve texture and balance acid/alkalinity. This absorption is accelerated as a result of the oxidative prosperities of the hydrogen ions reaction with natural mineral composition of the vegetables. CaCl 2 and CaCO3 fortified with MgOH, KOH protect the cell structure and improve the texture and firmness of the vegetable piece during the partial removal of free water in the drying process and during freezing. Each vegetable has a targeted free moisture removal in the drying process to concentrate the flavor, color and texture prior to freezing. (Provide Chart by Vegetable)

The CaCO 3 , MgOH, KOH, is used to alter the pKa and thus reduces the pH and neutralize the bitter taste of CaCl 2 resulting in an improve flavor balance in the finished vegetable pieces. This balance is exhibited in a smoother and fresher flavor than conventionally processed vegetables. The astringent flavor note typically detected in frozen or thermally processed vegetables utilizing CaCl 2 , citric acid or other calcium based minerals to improve texture is absent.

Gum acacia acts as a binder for the minerals and insures an even distribution during dilution into the liquid media to be applied to the vegetables. The binder does not precipitate during dilution and aids in the even distribution of the pKa modifier to the vegetables during processing.